Wall structure and method

ABSTRACT

A METHOD OF PANELING A WALL BY PLUMBING A FIRST PANEL CONNECTOR TRUE VERTICAL TO RECEIVE ONE VERTICAL EDGE OF A PANEL, SECURING THE FIRST CONNECTOR TO A BASE WALL, SNAPFITTING A SECOND PANEL CONNECTOR TO THE OTHER VERTICAL PANEL EDGE OF THE PANEL, SNAP-FITTING THE ONE VERTICAL PANEL EDGE TO THE FIRST PANEL CONNECTOR AND THEREBY POSITIONING THE SECOND PANEL CONNECTOR AGAINST THE BASE WALL, AND SECURING THE SECOND PANEL CONNECTOR TO THE WALL. THE PANEL CONNECTORS ARE OF AN ELONGATED, REINFORCED CONSTRUCTION WHICH CAN EXTEND SUBSTANTIALLY THE FULL HEIGHT OF THE PANEL MEMBERS AND ARE PROVIDED WITH OPENINGS FOR RECEIVING FASTENING MEANS THERETHROUGH INTO THE WALL. CONNECTOR-SPLICERS ARE PROVIDED FOR SPACED-APART PANEL CONNECTORS AND HAVE FASTENER-RECEIVING MEANS. CORNER TRIM CONNECTORS COVER THE EXPOSED INNER AND OUTER CORNERS OF THE BASE WALL.

Dec. 14, 1971 R. P. LlcKLl'n-:R ET AL WALL STRUCTURE AND METHOD /NV/iN'l'URS ROBERT L/C/(L/TER EARL ABBOTT' By JoH/v E @fsf/s A T TORNEYS Dec. 14, 1971 R. P. LICKLITER ETAL 3,626,550

WALL sTRUCTUREyAND METHOD Filed Sept. 5, 1968 l l 2 Sheets-Sheet 2 NVENTOR. ROBERTRL/CKL/TER EARL ABBOTT BY JOHNE REEVES ATTORNEYSY ,Y

United States Patent O 3,626,650 WALL STRUCTURE AND METHOD Robert P. Lickliter and Earl Abbott, Hamburg, and John F. Reeves, Tonawanda, N.Y., assignors to Flangeklamp Corporation, Buffalo, N.Y.

Continuation-impart of application Ser. No. 7 03,955, Feb. 8, 1968. This application Sept. 3, 1968, Ser. No. 756,853

Int. Cl. E04b 1/38; E04c 3/32 U.S. Cl. 52-288 8 Claims ABSTRACT or THE DISCLOSURE A method of paneling a wall by plumbing a rst panel connector true vertical to receive one vertical edge of a panel, securing the lirst connector to a base wall, snapfitting a second panel connector to the other vertical edge of the panel, snap-fitting the one vertical panel edge to the first panel connector and thereby positioning the second panel connector against the base Wall, and securing the second panel connector to the wall. The panel connectors are of an elongated, reinforced construction which can extend substantially the full height of the panel members and are provided with openings for receiving fastening means therethrough into the wall. Connector-splicers are provided for spaced-apart panel connectors and have fastener-receiving means. Corner trim connectors cover the exposed inner and outer corners of the base wall.

CROSS-REFERENCE TO A RELATED APPLICATION This application is a continuation-in-part of application Ser. No. 703,955 tiled Feb. 8, 1968 on a Wall Structure, now U.S. Patent No. 3,537,217 issued Nov. 3, 1970.

BACKGROUND OF THE INVENTION This invention relates generally to the construction art, and more particularly to certain new and useful wall paneling constructions and a new and useful wall paneling method.

In paneling a wall, it is customary to first aix the necessary furring strips to the wall at spaced intervals and then apply the paneling thereto. In modular wall constructions the furring strips must be accurately positioned to receive the panel edges, a gauge block or the like sometimes being used to aid the installer in maintaining the requisite spacing between the vertical edge-receiving furring strip members. Where the furring strips are metal connectors for receiving metal panels, the need for accuracy in this respect is particularly great.

It is readily apparent that considerable time is lost in precisely positioning furring strip panel connectors to receive modular metal panels and that the labor involved adds substantially to the cost of such paneling.

SUMMARY OF THE INVENTION Accordingly, it is an object of the present invention to provide a faster and more eicient method of paneling such a wall.

It is another object of this invention to provide a method of paneling a wall in which only one panel connector need be plumbed for a series of wall panel sections in a horizontally extending wall panel construction.

It is a further object of the present invention to provide a panel connector having means facilitating the g3,626,650 Patented Dec. 14, 1971 securement of the panel connector to a construction wall.

It is still another object of this invention to provide means for splicing spaced-apart panel connectors to provide a rigid panel connector assembly.

An additional object of the present invention is to provide wall panel construction having inner and outer corner trim pieces for enclosing inside and outside corners of a wall structure.

Yet another'object of this invention is to provide a new and improved panel connector assembly including a bracket -joining spaced panel connectors and having offset fastener-receiving means for holding the assembly against a base wall.

In carrying out the present invention, a first panel conf nector is positioned true vertical and secured to a masonry Wall to receive one edge of a wall panel. Shims can be in'- serted between the connector and the wall. A second panel connector is attached to the other edge of the panel and is carried by the panel against the wall as the panel is placed in position with its one edge attached to the lirst connector. The second panel connector is thereby positioned by the panel in properly spaced relation to the 'rst connector. The second connector then is secured to the Wall and the process is repeated for the entire length of the Wall.

The foregoing and other objects, advantages and characterizing features of the present invention will become clearly apparent from the ensuing detailed description of certain illustrative embodiment thereof, taken together with the accompanying drawings wherein like reference numerals denote like parts throughout the variouse views.

BRIEF DESCRIPTION OF THE DRAWING FIGURES FIG. l is a fragmentary perspective view of a single wall panel construction erected in accordance with the principles of the present invention;

FIG. 2 is a fragmentary, horizontal sectional view, on on enlarged scale, of the inside corner portion of FIG. 1;

FIG. 3 is a fragmentary, front elevational view of a panel connector of the present invention;

FIG. 4 is a fragmentary, front elevational view of a panel connector assembly of the present invention;

FIG. -5 is a fragmentary, perspective view of a splicer element shown inserted in the end of a panel connector;

FIG. 6 is a front elevational view of another panel connector assembly showing a clamp bracket in conjunc tion with spaced-apart panel connectors;

FIG. 7 is a side elevational view of the panel connector assembly of FIG. 6; and

FIG. 8 is a fragmentary, horizontal sectional View illustrating a corner trim connection for an outer wall corner.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to the drawings and particularly to FIG. l, there is shown a single Wall panel construction comprising panel members 10 attached to a masonry wall 12 in which the elongated horizontally extending paneled walls meet to form an inside corner. Although reference is made to a masonry Wall, it should be understood that the invention can be practiced with any permanent or temporary base wall structure.

In accordance with the present invention, panels 10 are mounted and supported in upright position against base wall 12 by means including panel connectors, generally designated x14, adapted to receive the side edge portions of the supported panels 10. Panel connector 14 can comprise a sheet metal fabrication of unitary, onepiece construction formed to provide a rectangular body portion having front face portions 16 and a rear face 18 joined and spaced apart by opposite side faces 20. Face portions 16 and face 18 are generally parallel and a pair of flange portions 22 extend outwardly from face portions 16 in a direction generally normal thereto, away from face 18. Face portions 16 and flange portions 22` thereby define a pair of corners adapted to receive the edge portions of adjacentpanel members 10, with panel members '10 resting against face portions 16. The metal or other sheet materialof which connectors 14 are fabricated also is folded over at the outer end of flange portions 22 to provide cam surfaces 24 leading to opposed shoulder portions 26, the opposite edges of the sheet material terminating within the opening provided between flange portions 22, as clearly shown for example in FIGS. 2 and 5. Panel connectors of this type are shown in Ser. No. 703,955.

In accordance with the instant invention, rear face 18 is provided with a plurality of openings 30, transversely paired and spaced longitudinally along the length of panel connector 14 for receiving fastening means in the form of screws 32 adapted to be threaded into insert plugs 34, preferably formed of wood, lead or plastic disposed in masonry wall 12. Openings 36, corresponding in number to openings 30, are provided in front face portions 16 of panel connector 14 and are coaxially aligned with but larger in diameter than, openings 30 to provide access for a work tool to the heads of screws 32. Obviously, openings 30 and 36 can receive fasteners other than screws.

Connector 14 also is formed to provide an internal channel having inwardly diverging side walls 40 leading to a rear wall 42 and providing a restricted inlet opening 44 through face 18. Channel 40-44 extends the full length of connector 14 in alignment with the opening between flange portions 22, the channel proper being confined within the rectangular body portion 16-20 of the connector as shown in FIGS. 2 and 5. Such internal channel is provided in the panel connector of Ser. No. 703,955 and is particularly useful in double wall constructions. It will be appreciated that channel 40-44 can be eliminated in connectors for single paneled wall constructions, if desired. However, it does no harm, and it also will be appreciated that the panel connectors 14 can be used interchangeably in either single or double wall constructions.

Each panel member includes a body 46 of gypsum, wall board or any other suitable material, covered with a skin 48 of metal or other thin sheet material which can be painted or decorated to provide any desired effect. Skin 48 extends beyond panel body 46 at its opposite side edge portions and is formed to provide an inturned skirt 50 adapted to be inserted between the flange portions 22 of adjacent connectors 14. Skirts 50 are formed to provide inturned shoulders 52 engaging behind connector shoulders 26 with a snap fit. Such snapfit skirts also can be provided along the top and bottom edge portions.

In paneling a wall in accordance with this invention, a panel connector 14 is positioned vertically in the manner of a furring strip against masonry wall 12 and plumbed so as to be in true vertical alignment for receiving one vertical skirt 50 of a panel 10 to form the leading end of a horizontally extending panel wall. lf necessary, shims can be inserted between connector 14 and wall 12. Connector 14 is secured to masonry wall 12 as by threading screws 32 into expansion plugs 34 inserted into openings formed in the wall. Then a second panel connector 14 is snap fitted to the other vertical skirt 50 of panel 10 with the inturned shoulder 52 thereof received between fiange portions 22 and behind shoulders 26. Panel 10 is then mounted on the fixed panel connector 14 by placing the unattached vertical edge of panel 10 against face 116 of fixed panel connector 14 with the shouldered skirt '50, 52 snap fitted in place between flange portions 22 and behind shoulder portions 26 of fixed panel connector 14. The second panel connector is carried into place and positioned by panel 10 as the latter is positioned against the first, previously positioned panel connector. Thus, panel 10 is employed as a gauge block to position the unattached panel connector 14 against masonry wall 12 in the properly spaced modular relation to the previously positioned connector. The second, unattached panel connector 14 then is secured to wall 12 in the same manner as previously described in connection with the first panel connector. The second panel connector then receives the second panel which carries the third panel connector into position, and the process 1s repeated for the entire length of the wall. In this way, an entire wall can be paneled quickly and easily, with only the first panel connector requiring plumbing and separate handling.

An adhesive 56 can be applied to face 18 in addition to, or in lieu of, screws 32 to insure a tight bond between panel connectors 14 and masonry wall 12. Also, nails can be substituted for screws 32, the nails being hammered into wall 12 by a driving implement.

Where it is desired to employ trim pieces along the top and bottom of the paneled wall, horizontally extending panel connectors 14 can be attached to the top and bottom edge skirts of panel 10 prior to attaching such panel to the vertically extending fixed panel connector 14. The horizontal connectors are then carried into position by panel 10 in the same manner previously described with reference to the vertical connectors.

A panel connector assembly, comprising a plurality of spaced-apart connectors held together by splicer elements, can be used instead of one, elongated panel connector. FIGS. 4 and 5 show a splicer element, generally designated 60, comprising a sheet metal fabrication of unitary, one-piece construction formed to provide a base 62 having a channel 64 of generally rectangular crosssection located centrally of the base and extending longitudinally of element 60, such channel having a front wall 66 and parallel side walls 68. Inturned flanges 70 and 72 extend from the lateral sides 0f base 62 in a direction generally normal to base 62 and parallel to side walls 68. Front wall 66 of channel 64 can be provided with longitudinally spaced openings 74 through which fastening means can be inserted to secure splicer element 60 to a base wall structure. Instead of openings, locating dimples or the like can be used to guide the installer when fastening. Splicer element 60 is adapted to be inserted into the adjacent ends of spaced-apart panel connectors 14 to connect the same together. It should be understood that a single elongated splicer element 60 extending the full height of the panel can be used instead of a plurality of relatively short splice elements 60, if desired, to provide added rigidity to the panel connectors. Splicer elements also project beyond the opposite ends of the connector assembly. When splicer elements are used in conjunction with panel connectors, the assembly is secured by fasteners, such as screws, nails and the like only in the area of the splicer element. The remaining portion of the assembly can be fastened by epoxy adhesive 56. Obviously, panel connectors 14 joined by splicer elements `60 can be used in double wall structures such as disclosed in Ser. No. 703,955, as well as in single wall structures, and can be positioned horizontally as well as vertically.

A clamp bracket, generally designated 61 (FIGS. 6 and 7) can be used in lieu of splicer elements 60 to connect spaced apart panel connectors. Clamp bracket 61 comprises an elongated plate 63 having a pair of projections or lugs 65 extending laterally from each side of plate 63 and adapted to extend into the adjacent ends of spaced panel connectors 14, or connector sections, and engage the inner surfaces of faces 18. Lugs 65 lie in a plane parallel to the plane of plate 63, offset therefrom to accommodate the thickness of faces 18 whereby plate 63 can lie fiat against wall 12 and lugs 65 can be contiguous with the inner surfaces of faces 18. An opening 67 is provided in that portion of plate 63 which projects beyond connectors 14, to facilitate the insertion of wall fastening or anchoring means. Since the fastening means are applied at a point offset from the adjacent panel connector, marring and deformation of the adjacent panel is precluded. If desired, a second opening 69 also can be provided on plate 63 in the area between adjacent panel connectors.

Bracket 61 can be reversed, either prior to insertion in the spaced panel connectors or by reversing the panel connector assembly, whereby the projecting fastener-receiving portion will extend from the side of the joined connectors 14 opposite the attached panel. The wall can be paneled from right to left, or vice versa, and the snapfit engagement between panel 10 and connectors 14 holds the latter against vertical movement, whereby bracket 61 need only hold them against wall 12.

Where an inside corner of a masonry wall 12 is to be paneled, it can be covered by an inner corner trim connector generally designated 76, having right angularly related faces 78 and 80 adapted to be attached to right angularly related panel connector 14 as shown in FIG. 2. Face 78 is provided with a shoulder 82 for snap-fitted engagement behind the shouldered connector flange 22 of one panel connector 14 while face 80 is maintained flat so as to be adjustable linearly relative to the shouldered connector fianges 22 of the other panel connector 14, dependent on the spacing between the right angularly related connectors 14.

Where an outside corner is to be enclosed an outer corner trim connector, generally designated 86, canbe employed as shown in FIG. 8. Trim connector 86 comprises right angularly related faces 88 and 90 having inturned skirts 92 and 94 provided with shoulders 96 and 98, respectively, for snap-fitted engagement behind the shoulders 26 of flanges 22 of right angularly related connectors 14 located on wall 12. As shown in FIG. 8, a side wall 20 of one panel connector 14 abuts face 88 of trim connector 86 to strengthen the same and provide rigidity and reinforcement therefor. Inner and outer trim connectors 76 and 78 are painted or decorated similarly to skin 48 of panels 10.

From the foregoing it is seen that the present invention fully accomplishes its intended objects and provides a novel and simple process for paneling a wall structure in an improved and more efiicient manner whereby only the initially erected panel connector need be plumbed and positioned in a true vertical plane and the panels serve as gauge blocks in spacing and aligning successive panel connectors. By the provision of connector-splicer elements, rigidity and strength are added to the overall panel connector assembly. Moreover, the assembly can be fastened to a wall at the splice connections to preclude deformation and weakening of the panel connectors. Also, clamp brackets can be employed in lieu of splicer elements to connect spaced-apart panel connectors and provide wall anchoring points offset from the attached panel. By the provision of inner and outer trim connectors, the exposed corners of the wall structure can be attractively covered.

Illustrative embodiments of this invention having been disclosed, it is to be understood that numerous modifications thereof can be made without departing from the spirit and scope of this invention as defined in the appended claims.

We claim:

41. A panel connector comprising: an elongated body member of generally rectangular configuration providing a pair of generally parallel panel receiving front face portions and a rear face connected t said front face portions by a pair of side faces; said rear face being adapted to be secured to a supporting s'urface; first openings provided in said rear face for receiving fastening means; and second openings provided in at least one of said front face portions in registry with said first openings for inserting fastening means therethrough together with a pair of generally parallel fla-nge portions extending from said front face portions in a direction generally normal thereto away from said rear face for receiving edge portions of wall panels in the corners provided by said flange portions and said front face portions.

2. A panel connector as set forth in claim 1, together with means providing shoulders on said iianges for interlocking with shouldered panel attaching means.

3. A panel assembly comprising: at least two coaxially aligned longitudinally spaced-apart panel connectors each having an elongated body member of generally rectangular configuration providing a pair of generally parallel front face portions and a rear face connected byia pair of side faces; means associated with said front face portions for receiving wall panel attaching means; and connecting means at least partially insertable into the adjacent ends of said connector body members and disposed therein wherein said panel connectors each have a channel disposed within said body members and opening through said rear face, and wherein said connecting means has a channel formation receiving portions of said channels of said spaced-apart panel connectors with a friction fit.

4. A panel connector assembly comprising: at least two co-aXially aligned longitudinally spaced-apart panel connectors each having an elongated body member of generally rectangular configuration providing a pair of generally parallel front face portions and a rear face connected by a pair of side faces; means associated with said front face portions for receiving wall panel attaching means; and connecting means at least partially insertable into the adjacent ends of said body connectors and disposed therein wherein said connecting means has a longitudinally extending channel formation and planar portions on opposite sides thereof engaging said rear faces of said spaced apart panel connectors, said planar portions having flanges engaging said side faces of said panel connectors.

5. The method of paneling a wall comprising: positioning a first panel connector in true vertical alignment against said wall; securing said first panel connector to said wall to receive one vertical edge of a panel; attaching a second panel connector to the other vertical edge of said panel; attaching said one vertical edge of said panel to said first panel connector, thereby positioning said second panel connector against said wall using said panel as a guide; a-nd securing said second panel connector to said wall to receive a vertical edge of another panel.

6. The method of claim 5, wherein said panel edges and said panel connectors interfit in snap-fit relation.

7. The method of paneling a wall according to claim 5 including selectively inserting shims between said panel connectors and said wall prior to securing said panel connectors to said wall.

8. The method of paneling a wall according to claim 5 including also attaching horizontally extending panel connectors to the top and bottom edges of said panel prior to attaching said one vertical edge of said panel to said first panel connector.

References Cited UNITED STATES PATENTS 1,253,764 1/1918 Zahner 52-720 1,726,500 8/ 7929 Norris 52-493 1,738,469 12/1929 Weiss 52-493 1,794,102 2/1931 Comins 52-4221 2,137,508 11/1938 Powell 52-378 2,211,384 8/1940 Patterson 52-732 (Other references on following page) 7 UNITED STATES PATENTS Jullien 52-493 Dunbar 52-493 Spiess 52,-493 Zinh 52-720 Grth et al. 52-242 Bohnsack 52-619 McCabe 52-481 Shannon 52-238 Spencer 52-481 Omholt 52-480 8 FOREIGN PATENTS 1,317,643 1/1963 France 287-18936 1,097,650 1/1961 *Germany 287-189.36

5 FRANK L. ABBOTT, Primary Examiner I. L. RIDGILL, JR., Assistant Examiner U.S. Cl. X.R. 

